Method of winding a stator



NOV. 30, 1955 ROBERTS 3,220,094

METHOD OF WINDING A STATOR Original Filed July 3, 1958 9 Sheets-Sheet 1INVENTOR. GEORGE l. ROBERTS HITOR/VEY 1955 G. I. ROBERTS METHOD OFWINDING A STA'I'OR Original Filed July 5, 1958 9 Sheets-Sheet 2INVENTOR. GEORGE ROBE RTS G. l. ROBERTS METHOD OF WINDING A STATOR Nov.30, 1965 9 Sheets-Sheet 5 Original Filed July 5,

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INVENTOR. GEORGE I. ROBERTS HITORA/EY Nov. 30, 1965 l. ROBERTS 3,220,094

METHOD OF WINDING A STATOR Original Filed July 5, 1958 9 Sheets-Sheet 4IN VEN TOR.

GEORGE I. ROBERTS BY z AT ORNEY Nov. 30, 1965 G- l. ROBERTS METHOD OFWINDING A STATOR Original Filed July 5, 1958 9 Sheets-Sheet 5 INVENTOR.GEORGE I. ROBERTS FIG. 7

ATTOIQIVE Y NOV. 30, 1965 ROBERTS 3,220,094-

METHOD OF WINDING A STA'IOR Original Filed July 3, 1958 9 Sheets-Sheet 6FIG. 8

IN VEN TOR.

I GEORGE 1. ROBERTS 1977'0KA/EY NOV. 30, 1965 L ROBERTS 3,220,094

A METHOD OF WINDING A STATOR Original Filed July 3, 1958 9 Sheets-Sheet7 IN VEN TOR.

GEORGE I, ROBE R719 BY Z b Nov. 30, 1965 5. I. ROBERTS METHOD OF WINDINGA STATOR Original Filed July :5, 1958 9 Sheets-Sheet 8 mxomhm l m PDImmZdE INVENTOR. GEORGE I. ROBERTS NOV. 30, 1965 ROBERTS 3,220,094

METHOD OF WINDING A STATOR Original Filed July 3, 1958 9 Sheets-Sheet 9LEFT WIRE -SHUTTLE STROKE HOOK ASSEMBLY F I --SHUTTLE STROKE D-' RIGHTWIRE 1 HOOK A/SSEMBLY FIG. 12C

RIGHT WIRE HOOK ASSEMBLY FIG. 12D

INVENTOR. GEORGE Z. ROBERTS United States Patent O 3,22%),094 METHOD OFWINDING A STATOR- George L Roberts, Maywood, NJL, assignor to The BendixCorporation, a corporation of Delaware Original application July 3,1958, Ser. No. 746,437, now Patent No. 3,061,211, dated Oct. 30, 1962.Divided and this application July 25, 1960, Ser. No. 45,119 7 Claims.(Ci. 29155.5)

The present application is a division of U. S. application Serial No.746,437, filed July 3, 1958, now Patent No. 3,061,211, granted Oct. 30,1962, by George I. Roberts, and assigned to Bendix Aviation Corporation.The invention relates to a novel coil winding process and moreparticularly to a novel method for winding field coils directly in slotsof stator or rotor units for motors, generators, synchros or the like.

An object of the invention is to provide a novel coil winding methodincluding the steps of passing winding wire through the bore of a statoror rotor unit; oscillating the unit relative to the wire so as to eifectthe necessary wire end turns on the unit; and picking up the wire fromthe opposite ends of the unit and selectively depositing the wire in endturn forming rings having inner and outer grooves. The end turn formingrings may be integral with the unit or may be of an expendible type suchas disclosed and claimed in US. Patent No. 2,810,848, granted October22, 1957, to George I. Roberts and assigned to Bendix AviationCorporation.

Another object of the invention is to provide a novel method forautomatically winding at the same time multiple field coils in the slotsof the unit.

Another object of the invention is to provide a novel method of windingwire on end turn forming rings mounted at opposite ends of a stator orrotor unit and having inner and outer grooves, including the novel stepsof depositing the wire in timed relation with the oscillation of theunit in such a manner as to wind coils first in one set of slots andthen in another set of slots in the unit and first in the inner groovesand then in the outer grooves in the end turn forming rings.

Another object of the invention is to provide in the aforenoted methodthe additional step of oscillating the unit so as to meet the pitchrequirements of the coils to be wound which may vary up to 200 or more,together with the additional step of varying the amount of oscillationso as to effect coils of different pitch.

Another object of the invention is to provide a novel method of windingcoils on a stator or rotor unit including the steps of placing the wiresof the coils in selected slots in the unit as required and in grooves ofend turn forming rings so as to effectively wind coils of apredetermined pitch and coils which cross over each other at the endsthereof in a predetermined pattern.

These and other objects and features of the invention are pointed out inthe following description in terms of the embodiment thereof which isshown in the accompanying drawings. It is to be understood, however,that the drawings are for the purpose of illustration only and are not adefinition of the limits of the invention, reference being had to theappended claims for this purpose.

In the drawings:

FIGURE 1 is a plan view of the coil winding apparatus with certain partsbroken away to more clearly show the construction thereof.

FIGURE 2 is a side elevation of the construction of FIGURE 1 withcertain parts broken away to better illustrate the construction thereof.

FIGURE 3 is an enlarged sectional view taken along the line 33 of FIGURE1 and looking in the direction of the arrows.

3,223,084 Patented Nov. 30,1965

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FIGURE 4 is an enlarged sectional view taken along the line 44 of FIGURE1 and looking in the direction of the arrows.

FIGURE 5 is an enlarged sectional view taken along the line 55 of FIGURE1 and looking in the direction of the arrows.

FIGURE 6 is an enlarged sectional view taken along the line 66 of FIGURE1 and looking in the direction of the arrows.

FIGURE 7 is an enlarged sectional view taken along the line 77 of FIGURE1 and looking in the direction of the arrows.

FIGURE 8 is an enlarged detail sectional view of the stator nest.assembly with expendable end turn forming rings mounted at opposite endsof the stator.

FIGURE 9' is an enlarged detail plan view of the right end of the statornest assembly with an expendable end turn forming ring mounted at saidend and three wound coils thereon.

FIGURE 10 is an enlarged detail plan view of the left end of the statornest assembly with an expendable en'd turn forming ring mounted at saidend and six wound coils thereon in the completed stage.

FIGURE 11A is a diagrammatic illustration of the wire end turn and hookassembly at the right hand side of the stator nest assembly of the coilwinding apparatus and showing the same at the start of the windingoperation and by dotted lines the step of positioning the hook assemblyso as to release the wire held thereby after the Wire bushing had beenpositioned into the bore of the stator nest assembly.

FIGURE 11B is a diagrammatic illustration showing first stages of thewinding operation in which the wire bushing is positioned in successivesteps through the bore of the stator nest assembly from the right handside to the left hand side thereof, together with a showing by dottedlines of the adjusted positions taken by the associated wire hookassembly during such stages in the winding operation.

FIGURE 11C is a diagrammatic illustration of the wire end turn andassociated wire hook assembly in operative relation at the left handside of the stator nest assembly and showing by dotted lines successivesteps in the positioning of the wire hook assembly to pick up the wirecarried by the wire bushing after passage thereof through the bore ofthe stator nest assembly from the right to the left hand side.

FIGURE 12A is a diagrammatic illustration of the wire end turn and hookassembly at the left hand side of the stator nest assembly after thefurther step of applying an oscillatory movement to the stator nestassembly and showing by dotted lines the positioning of the associatedwire hook assembly so as to release the wire held thereby following areturn movement of the wire bushing back into the bore of the statornest assembly.

FIGURE 12B is a diagrammatic illustration of further stages in thewinding operation in which the wire bushing is shown positioned insuccessive return steps through the bore of the stator nest assemblyfrom the left hand side to the right hand side thereof, together with ashowing by dotted lines of the adjusted positions- FIGURE 12D is adiagrammatic illustration of the wire end turn and hook assembly at theright hand side of the stator nest assembly and showing by dotted linesthe adjusted positions of the associated wire hook assembly to pick upthe wire carried by the wire bushing on the return passage thereof tothe right hand side of the stator nest assembly.

FIGURE 12B is a diagrammtic illustration of the wire end turn and hookassembly at the right hand side of the stator nest assembly after thefinal step of applying an oscillatory movement to the stator nestassembly in the completion of the winding of one turn of wire and thereturn of the stator nest assembly to the initial position in relationto the associated wire hook assembly of FIG- URE 11A preparatory to thewinding of succeeding turns of wire in a similar manner to thatheretofore diagrammatically shown.

Referring to the drawings of FIGURES 1 through 8, a typical coil windingapparatus in which the method of the invention may be applied isindicated generally by numeral 14 and includes a base plate 15 on whichare mounted the necessary structures for operation of the several partsin accordance with the respective steps of the novel coil windingmethod. The apparatus may include a split bearing 17 for loading andunloading stator units for the coil winding process and a motor 19 fordriving the gearing 21, counter unit 23 and coil Winding apparatusindicated generally by the numeral 14.

The coil winding apparatus 14 may include suitable mechanism, not shown,such as a jaw tooth clutch of conventional type operated by a levercontrolled by the counter unit 23 so as to automatically disconnect themotor 19 from driving relation with the coil winding apparatus and stopthe apparatus after completion of a predetermined number of coilwindings for which the counter unit 23 has been set or the disconnectionof the motor 19 may be manually controlled by the operator through alever 22 and the coil winding apparatus brought to a stop uponcompletion of the desired number of windings indicated by the counterunit 23.

A stator unit or shell 24 and stator nest assembly 25 are shown indetail in assembled relation in FIGURE 8, while as shown in detail inthe coil winding apparatus of FIGURES 3 and 4, the stator nest assembly25 is placed in a lower section 27 of the split bearing 17 and includesa stator nest member 26 to which there is secured by screws 28 a ringgear member 29. In order to effect proper alignment of the teeth of thering gear 29 of the stator nest assembly 25 with teeth of a drive gear31 and properly index the position of the teeth of the driven gear 29with that of the driving gear 31 there is provided an alignment assembly33, shown in FIGURE 4. The alignment assembly 33 is so arranged as toprohibit the gears 29 and 31 from meshing, except when the stator nestassembly 25 has been rotated to a proper index position with relation tothe coil winding apparatus when loading.

The assembly 33 includes an alignment pin 35 biased by a spring element37 against the periphery of an index collar 39. The index collar 39includes a slot 41 cooperating with the alignment pin 35 and so arrangedas not to allow the gears 29 and 31 to mesh until the slot 41 in theindex collar 39 is adjusted to a predetermined position. This positionis effected when the index collar 39 is so adjusted relative to the pin35 as to allow the alignment pin 35 to enter the slot 41 at which timethe driving gear 31 and the driven gear 29 are in mesh in the properindex position. The index collar 39 is secured to the stator nest member26 by fastening elements 42, as shown in FIG- URE 10.

The split bearing 17 has a cap portion 43 pivoted at 45 in ananti-clockwise direction to the closed position and includes a pin 47 inthe bearing cap 43 arranged to operatively engage a lever 49 pivoted atone end at 51. An op- 4 posite end of the lever 49 is in operativecontact with a flange portion 50 of the alignment pin 35 and so arrangedas to act on the flange 50 so as to slide the alignment pin 35 out ofengagement with the slot 41 upon closure of the bearing cap 43' andthereupon permit rotation of the stator nest 25 free of the alignmentpin 35. The bearing cap 43 may be conveniently clamped and held inposition by a hinged bracket 52 and thumb nut 53.

A detent assembly 54, shown in FIGURES 3 and 4, is secured to the capportion 43 and includes a spring biased detent element 55 cooperatingwith suitable openings 56 in the index collar 39 at the extreme 160degree and 120 degree adjusted positions of the stator nest, as shown inFIGURE 10, so as to avoid misalignment of the stator nest assembly 25due to lost motion between'teeth of the gearing 29 and 31 and gear train91-93, linkage 83-87 and play in cam roller 81.

As best shown in FIGURES l and 2, the coil Winding apparatus is drivenfrom the electric motor 19 through gearing 21 and worm gear 57cooperating with gearing 59 so as to effect rotation of shaft 61. Theshaft 61 in turn drives shaft 63 through helical gears 65 and 67, asshown in FIGURES 1 and 7, while shaft 63 drives a shaft 69 throughhelical gears 71 and 73. The three shafts 61, 63, and 69 are journaledin suitable roller bearings carried by supporting members 70, 72, and74, as shown in FIG- URES l-2 and 7.

Functional component assemblies operated from the driven shafts 61, 63and 69 include stator nest oscillation mechanism, shuttle reciprocationmechanism and wire hook finger assemblies located at opposite sides ofthe stator nest assembly 25, as will be described hereinafter.

Stator nest oscillation mechanism The stator nest oscillation mechanism,as shown in FIGURES l and 4, includes cams 75 and 76 keyed to andaxially slidable on the shaft 63. The cam 75 is a suitable track camwith a rise design to oscillate the stator nest assembly 25 for 160degrees in each direction through suitable mechanical mechanism and isdriven by the shaft 63, as best shown in FIGURE 4. The cam 75 contacts aroller 81 projecting from a lever 83 pivoted at 85 and connected by alink 87 so as to rotate gear stud 89 on which is assembled a gear 91, asshown in FIGURE 5, and which gear 91 meshes with a gear 93, as shown inFIGURES 1, 2 and 3, at a one to four step-up ratio.

The gear 93, as shown in FIGURE 3 is keyed to a shaft 95 on which ismounted bushing 97, spring retainer 99, spring 101, drive gear 31 andbushing 105. The spring retainer 99 and drive gear 31 are keyed to shaft95 and the drive gear 31 is held in mesh with the stator nest gear 29 byspring 101. This assembly is journalled in split bearings 107, as shownin FIGURE 3.

As the cam 75 rotates, the stator nest 25 is rotated to exactly 160degrees and then dwells a specified interval of time at the rotatedposition and thereafter is rotated back to the original position whereit dwells again for the same dwell time. This operation is accomplishedby means of the cam 75 through the linkages and gears, heretoforedescribed, for Winding the 160 degree coils, as will be hereinafterexplained in greater detail.

In order to wind a second set of 120 degree coils, it is necessary tobring into operative relation the cam 76 in place of the cam 75 anddisengage the stator nest driven gear 29 from the drive gear 31 so thatthe stator nest 25 may be rotated to a new index position for effectingthe latter operation.

To change the track cam 75, there is provided a thumb nut 110, shown inFIGURES 1 and 4, which upon loosening permits a bracket 112 to beshifted to the left, as shown in FIGURE 1, so as to axially shift thecams on shaft 63 and place the second track cam 76 into contactingrelation with the roller 81, while withdrawing the roller 81 fromcontacing relation with the cam 75. Upon such adjustment of the bracket112, the thumb nut inay be tightenend so as to hold the bracket 112 andcam 76 in the readjusted position. The cam 76 is so arranged thatthrough the cam linkages and gears previously described with referenceto cam 75, the cam 76 may now operate so as to oscillate the stator nestassembly over the second 120 degree range.

In order to rotate the stator nest assembly 25 to the new index positionfor winding the second set of 120 degree coils without rotating thedrive gear 31, there is provided a knurled plate 115, shown in FIGURE 3,slidably mounted on a bearing member 117 carried by supporting member119 and having pins 121 projecting from the plate and so arranged thatupon movement of the plate 115, as shown in FIGURES 1, 2 and 3, to theright, the pins 121 contact an adjacent face surface of the gear 31 andin turn move the gear 31 to the right against the tension of spring 101.The latter adjustment effectively disengages the drive gear 31 from meshwith the gear 29 so that the stator nest assembly 25 may thereupon bereadjusted to a new index position for the second or degree coil windingrange.

Shuttle reciprocating motion Motion of a shuttle 125, shown in FIGURE 2,is effected by means of a track cam 127, shown in FIGURE 7, keyed to theshaft 69 and contacting a roller 129 projecting from a lever 131 pivotedat 133 and connected by means of a link 135 to a gear 137. The motionimparted to gear 137 is transmitted through step-up ratio gear train138, 139 and 140, as shown in FIGURES 1, 2 and 3, to a gear 141 which,as shown in FIGURE 2, meshes with a gear rack 143. The gear rack 143 isattached at 144 to the shuttle 125 and slidably mounted in a slot 145provided in a bearing sleeve 146 so that the shuttle 125 may slide backand forth in the bearing sleeve 146 carried at one end by the supportingmember 147 and secured at the opposite end at 148 to a supporting member149.

Attached to the shuttle 125 at its innner end is a shuttle cap 150having a plurality of wire slots or bushings 152. In the describedapparatus there are three (3) wire slots 152 located 120 degrees apart.The shuttle 125, as shown in FIGURE 2, is keyed in the bearing sleeve146 by a pin 151 slidable in a slot 153 so that there is no rotation ofthe shuttle cap 150.

Further, rotation of the track cam 127 (FIGURE 7) imparted by shaft 69acts through the gear rack 143 (FIGURE 2) so as to slide the shuttle cap150 (FIG- URE 3) through the bore of the stator unit 24 (FIG- URE 8)normally positioned in the stator nest assembly 25 and into contact withwall surfaces defining a hole 155 in a bearing member 157 carried bysupporting members 119 and 158, as shown in FIGURE 3, so as to providerigidity while shuttle 125 is stationary and the stator nest assembly isrotated. The shuttle cap 158 then returns through the stator nest to itsposition at the right of the stator nest assembly 25 where it againremains stationary until the stator nest assembly 25 has nearlycompleted its cycle of rotation, as hereinafter explained.

Wire hook finger assemblies and vertical and lateral motion thereofPositioned at opposite sides of the stator nest assembly 25 are wirehook finger assembles 160 and 160A, shown in FIGURES 2 and 3, andincluding housings 162 and 162A having inner bearing collars 163 and163A, as shown in FIGURE 3, slidably mounted on bearing sleeve 146 andbearing member 157, respectively.

Mounted in the housings 162 and 162A are Wire hook finger elements 164and 164A (FIGURE 3) each of which has a wire hook pin element 165 or165A at its free end while the opposite end thereof is pivotallyconnected at 166 or 166A to the respective housings. The respectivefingers have cam surfaces 168 and 168A cooperating with roller elements170 and 170A carried by arms, 171 and 171A projecting from collars 1'72and 172A slidably" mounted on the bearing collars 163 and 163A withinthe housings 162 and 162A. Coiled spring members 174 and 174A surroundthe housings 162 and 162A and act on outer edge surfaces of the fingersto bias the Wire hook fingers 164 and 164A into contacting relation withthe respective rollers 170 and 178A.

A cam 188 (FIGURE 3) keyed to the shaft 69 controls vertical motion ofthe wire hook fingers 164 and the lateral position of the housing 162only when being moved toward the stator nest assembly 25. In contactwith the cam 180 is a roller 182 projecting from a lever 183 pivoted at184. The lever 183 is connected by a link 185 to a bifurcated yoke lever186 pivoted at 181. The bifurcated yoke portion of the lever 186 hasprovided at the free ends thereof pin portions 187 which project into anannular groove 188 provided in the collar 172 slidably mounted on theinner bearing collar 163 of the housing 162 so that the housing 162 isfree to rotate on the bearing sleeve 146 and relative to the lever 186while the lever 186'may etfect an adjustment of the collar 172 withinthe housing 162 on collar 163 to cause a corresponding adjustment of therollers 170 cooperating with the cam surface 168 of the fingers 164 tovertically adjust the fingers.

Thus, the control cam 180 cooperates through the described mechanism toelevate the fingers 164 to the position shown by the sliding of theroller elements 170 relative to the cam surfaces 168 and Within thehousing 162 toward the stator nest 25.

When the fingers 164 have reached the position shown in FIGURE 3, thecollar 172 carrying the arms 171 and roller elements 170 makes contactwith a lateral ring,189 positioned in the bearing collar 163 so thatfurther increase of rise in cam 180 acts to move the housing 162 and theentire assembly 160 toward the stator nest 25 to a predeterminedposition.

The fingers 164 will remain in the elevated position, since there hasbeen no change in the position of the roller elements 178 within thehousing 162 and relative to the cam surfaces 168 of the fingers 164. Thehousing 162 is free to be moved in a lateral direction toward the statornest 25 on the bearing sleeve 146 by the force exerted through the lever186, collar 172, ring 189 and collar 163.

The lateral return motion of the housing 162 away from the stator nest25 is elfected by means of a control cam 190 afiixed to shaft 69. Incontact with the cam 199 is a roller 192 projecting from a lever 194pivoted at 195. The lever 194 is connected by a link 197 to a bifurcatedyoke lever 199 pivoted at 200. The bifurcated yoke portion of the lever199 has provided at the free ends thereof pin portions 201 whichoperatively contact an end portion of the bearing collar 163 when therise of cam 190 is in contact with roller 192.

Moreover, the control cams 180 and 190 are so designed that operation ofthe yoke lever 186 in motion of housing 162 away from the stator nest 25precedes that of yoke lever 199 by approximately two (2) degrees, whilein motion of housing 162 toward the stator nest 25, the yoke lever 199precedes that of yoke lever 186 by the same approximate two (2) degrees.In such lateral adjustment there is no change in the elevation level ofthe fingers 164, since there has been no change in lateral rela tionshipbetween the housing 162 and the roller elements 170 or in therelationship between the roller elements 170 and the cam surfaces 168 ofthe fingers 164.

In this connection when the cam roller 192 reaches the top of the riseon the control cam 190, the lateral motion of the housing 162 away fromthe stator nest assembly 25 is stopped by a retainer ring 210 mounted onthe bearing sleeve 146. With the housing 162 in such lateral position,as shown in FIGURE 3, a further drop in the surface of the control cam180 allows the fingers 164 to drop to a lower position, since the rollerelement 170 is then moved within the housing 162 in a direction awayfrom the stator nest assembly through the action of the bifurcated yokelever 186 in controlling the position of the collar 172 on the sleeve163.

The position of the fingers 164 is now such that when the housing 162 isrotated as hereinafter explained, the pins 165 of the three fingers 164will be positionedunder three separate wire strands and ready to pick upthe wires in the coil winding operation, as will be explainedhereinafter under the heading Description of Operation with reference toFIGURES 11A to C and 12A to E.. The rollers 182 and 192 of the levers183 and 194 are maintained in contact with the respective control cams180 and 190 by means of a spring 212 connected at op posite ends to thelevers 183 and 194, as shown in FIG- URE 3.

In order to control the operation of the wire hook finger assembly 160Aat the opposite side of the stator nest 25, there is provided a cam 229keyed to shaft 61. The cam 220 controls vertical motion of the wirehoo'k fingers 164A and the lateral position of the housing 162A onlywhen the housing 162A is being moved toward the stator nest assembly 25.

In order to elfect the foregoing operation, there is provided in contactwith the cam 220 a roller 222 projecting. from a lever 224 pivoted at226. The lever 224 is con-- nected by a link 228 to a bifurcated yokelever 230* pivoted at 232. The bifurcated yoke portion of the lever 230has provided at the free ends thereof pin portions 235 which projectinto an annular groove 238 provided. in the collar 172A slidably mountedon the inner bearing; collar 163A of the housing 162A so that thehousing 162A is free to rotate on the bearing member 157 and relative tothe lever 230, while the lever 230 may effect an adjustment of thecollar 172A within the housing 162A on collar 163A to cause acorresponding adjustment of the rollers 170A cooperating with the camsurface 168A of the fingers 164A to vertically adjust the fingers.

Thus, the control cam 220 cooperates through the described mechanism toelevate the fingers 164A to the position shown by the sliding of theroller elements 170A relative to the cam surfaces 168A and within thehousing 162A toward the stator nest 25.

When the fingers 164A have reached the position shown in FIGURE 3, thecollar 172A carrying arms 171A and roller elements 170A makes contactwith a lateral ring 189A positioned in the bearing collar 163A so thatfurther increase of the rise in cam 220 acts to move the: housing 162Aand the entire assembly 160A toward the stator nest 25 to apredetermined position.

The fingers 164A will remain in the elevated position, since there hasbeen no change in the position of the roller elements 170A within thehousing 162A and relative tothe cam surfaces 168A of the fingers 164A.The housing 162A is free to move in a lateral direction toward thestator nest 25 on the bearing member 157 by the force exerted throughthe lever 230, collar 172A, ring 189A and collar 163A.

The lateral return motion of the housing 162A away from the stator nest25 is effected by means of a control cam 250 also affixed to shaft 61.In contact with the cam 25!} is a roller element 252 projecting from alever 254 pivoted at 255. The lever 254 is connected by a link 257 to abifurcated yoke lever 259 pivoted at 260. The bifurcated yoke portion ofthe lever 259 has provided at the free ends thereof pin portions 261which operatively contact an end portion of the bearing collar 163A whenthe rise of cam 250 is in contact with roller 252.

Moreover,'the control cams 220 and 250 are so designed that operation ofthe yoke lever 230 of housing 162A away from the stator nest 25 precedesthat of yoke lever 259 by approximately two (2) degrees, while inmovement of the housing 162A toward the stator nest 25 the yoke lever259 precedes that of yoke lever 230 by the approximate two (2) degrees.In such lateral adjustment there is no change in the elevation level offingers 164A, since there has been no change in lateral relationshipbetween the housing 162A and the roller elements A or in therelationship between the roller elements 170A and the cam surfaces 168Aof the fingers 164A.

In this connection when the cam roller 252 reaches the top of the riseon the control earn 250 the lateral motion of the housing 162A away fromthe stator nest assembly '25 is stopped by a retainer ring 265 mountedon the hearing member 157. With the housing 162A in such lateralposition, as shown in FIGURE 3, a further drop in the :surface of thecontrol cam 220 allows the fingers 164A to drop to a lower position,since the roller element 170A is then moved within the housing 162A in adirection away from the stator nest assembly 25 through the action ofthe bifurcated yoke lever 230 in controlling the position of the collar172A on the sleeve 163A.

The position of the fingers 164A is now such that when the housing 162Ais rotated, as hereinafter explained, the pins 165A of the three fingers164A will be positioned under three separate wire strands and ready topick up the wires in the coil winding operation as will be explainedlater under the heading Description of Operation with reference toFIGURES 11A to C and 12A to E. The rollers 222 and 252 of the levers 224and 254 are maintained in contact with the respective control cams 220and 250 by means of a spring 267 connected at opposite ends to thelevers 224 and 254, as shown in FIG- URE 3.

The above descriptions with reference to the wire hook finger assembliescovers the operative parts in the vertical and lateral motion of thefingers in the winding of the first three crossover coils, shown inFIGURE 9, within the first predetermined range of, for example, 160degrees. In order to wind the second set of three coils, shown in FIGURE10, within a different range of, for example, 120 degrees, it isnecessary to change the control cams which effect the movement of thewire hook assemblies in the lateral direction.

In the present mechanism, therefore, there is provided novel means forreplacing the control cams 229 and 250 on the left side and the controlcams and on the right side of the mechanism, as shown in FIGURE 3, bycontrol cams 270 and 272 (FIGURE 6) and by control cams 274 and 276(FIGURE 5), respectively.

In the latter mechanism there is provided latch members 286 and 285, asshown in FIGURES 2, 5 and 6, arranged to engage in channels 287 and 289provided in actuating rods 291 and 293, respectively. The actuating rods291 and 293 in turn serve to adjustably position brackets 295 and 297between which are positioned, respectively, the control cams 220, 250,270, 272 and the control cams 180, 190, 274 and 276 axially slidable onand splined at 298 and 299 to the.- shafts 61 and 69, respectively.

The latch members 281? and 285 may be pivotally adjusted on pivot pins302 and 303 out of engagement with the channels 287 and 289upon movementof latch members on pins 300 and 301 whereupon actuating rods 291 and293 may be pushed inward toward the rear of the machine and the latchmembers 280 and 285 brought into locking engagement with the channels305 and 307 of the actuating rods 291 and 293, respectively.

In the latter adjusted position of the actuating rods 291 and 293 thecontrol cams 220 and 250 are replaced axially in operative relation bycontrol cams 270 and 272 and control cams 180 and 190 are replacedaxially in operative relation by control cams 274 and 276. The controlcams 270', 272, 274 and 276 thereupon operate through the linkagespreviously described to change the lateral position of the wire hooklever assemblies 169 and 160A, to effect the desired operation thereoffor w1nding the second set of three coils within a diiferentpredetermined range of, for example, 120 degrees.

Rotation of wire hook finger assembly Rotation of the wire hook fingerassembly 160 on the bearing sleeve 146 and rotation of the wire hookfinger assembly 160A on bearing member 157 is effected through mechanismhereinafter described to provide the desired winding operation.

The rotation of housing 162 is effected by a cam 310 mounted on shaft 63and shown in FIGURES 1 and 5. In contact with the cam 310 is a rollerelement 312 Which, as shown in FIGURE 5, projects from a lever 314pivoted at 316 connected by link 318 through another lever 320 pivotedat 322. The lever 326 has attached to it a link 3224 which is in turnoperably connected to a pin 326 of the wire hook finger assembly 160, asshown in FIGURE 1. A spring 330 biases the lever 320 in acounterclockwise direction and the finger assembly 160 in acounterclockwise direction while tending to maintain the roller 312 incontacting relation with the surface of the cam 310.

The function of the cam 310 is to rotate, through the linkage described,assembly 160 containing the wire hook fingers 164. Rotation of thefinger assembly 160 in a counterclockwise direction rotates the fingers164 and thereby the wire hook pin elements 165 away from the wire beingwound through the stator slot, while rotation of the assembly 160 in aclockwise direction rotates the fingers 164 and thereby the wire hookpin elements 165 to a position under the wire after the shuttle 125 hasreached its extreme right position. This operation will be explainedmore in detail later with reference to FIG- URES 11A to C and 12A to E.

The bearing for rotation of the assembly 160 is the bearing sleeve 146,while the link 324 is supported in a groove in a mounting plate 325 soas to allow for smooth lateral operation of the wire hook fingerassembly 160. The actuating pin 326 is slidably mounted in a hole at oneend of the link 324 to permit the lateral operation of the wire hookfinger assembly 160.

Similarly the rotation of housing 162A is effected by cam 350 mounted onshaft 63 and shown in FIGURES 1 and 6. In contact with the cam 350' is aroller ele ment 352 which, as shown in FIGURE 6, projects from a lever354 pivoted at 356 and connected by a link 358 to another lever 360pivoted at 362. The lever 360 has attached to it a link 364 which is inturn operably connected to a pin 366 of the wire hook finger assembly160A, as shown in FIGURE 6. A spring 370 biases the lever 360 in acounterclockwise direction and the finger assembly 160A in acounterclockwise direction, while tending to maintain the roller 352 incontacting relation with the surface of the cam 350.

The function of the cam 350 is to rotate through the linkages described,assembly 160A containing the wire hook fingers 164A. Rotation of thefinger assembly 160A in a counterclockwise direction rotates the fingers164A and thereby the wire hook pin elements 165A away from the wirebeing wound through the stator slot while rotation of the assembly 160Ain a clockwise direction rotates the fingers 164A and thereby the wirehook pin elements 165A to a position under the wire as the shuttle 125has reached the extreme left position. This operation will be explainedmore in detail later with reference to FIGURES 11 and 12.

The bearing for rotation of the assembly 160A is the bearing member 157(FIGURE 3) while the link 364 is supported in a groove in a mountingplate 371 (FIG- URE 6) so as to allow for smooth lateral operation ofthe wire hook finger assembly 160A. The actuating pin 366 is slidablymounted in a hole in one end of the link 364 to permit the lateraloperation of the wire hook finger assembly 160A.

In the preceding description of the several operating parts of themachine no attempt has been made to tie in the timing in the variousoperations which is described hereinafter under the heading Descriptionof Operation.

16 Description of operation Before machine winding the stator unit 24,the unit has to be rotated in the stator nest assembly 25 to a definiteadjusted position, as shown in FIGURES 8, 9 and 10. The stator nestassembly is comprised of the following parts indicated by thecorresponding numerals:

26stator nest 39index collar 29gear 400bearing 402-spring for statorslide pin 4tl4stator slide pin 406cam pin 408-retainer screw 410wi-refastening pins 412-wire guide pins 2'8gear mounting screws The statorunit 24 is placed in the bore of the stator nest 26 and located on asuitable indexing fixture so that the surfaces of the stator unit 24 areapproximately flush with surfaces of the stator nest 26. The stator unit24 is then rotated so that a predetermined slot, for example, slot 111in the stator unit 24, lines up with a scribed line 414, shown in FIGURE10, and thereby with the center point of the index hole 56 in indexcollar 39, shown in FIGURE 8, as well as the left edge of a wire guidepin 412 on the stator nest 26, shown in FIGURE 9. The stator unit 24 isheld in index position by the camming action of the cam pin 406 on slidepin 404 when the retainer screw 408 is tightened in position, as shownin FIGURE 8.

End turn forming rings or similar end caps 420 and 422 are now attachedto the stator nest 26 and stator unit or shell 24. These rings are sokeyed that the same are assembled in one predetermined position onlyrelative to stator unit 24. The stator nest assembly 25 is thenassembled in the winding machine as shown in FIGURE 3. The end turnforming rings 420 and 422 may be of the type described and claimed inUS. Patent No. 2,810,848, granted October 22, 1957, to George I.Roberts, and assigned to Bendix Aviation Corporation.

The end turn forming rings or end caps 420 and 422 each have, as shownin FIGURE 8, outermost, intermediate, and innermost flanges. Theinnermost and intermediate flanges of the respective end caps 420 and422 define therebetween grooves, channels or innermost wire end turnreceiving zones 435 and 437 while the outermost and intermediate flangesof the respective end caps 420 and 422 define therebetween grooves,channels or outermost wire end turn receiving zones 439 and 441.Furthermore, the end caps 420 and 422, as shown in FIGURES 9 and 10,respectively are provided with radially extending slots indicated byRoman numerals I, II, III, IV, V, VI, VII, VIII, and IX adapted toregister with corresponding radially extending slots in the stator unitor shell 24 to be wound, one of said end caps 420 and 422, as shown inFIGURE 8, are applied to each end of the stator unit or shell 24 to bewound with the slots in the end caps 420 and 422 in register with thecorresponding slots in said stator unit or shell 24.

The described machine is designed to wind three (3) coils at one time,winding coils in stator slots III-VII, I-VI, and IV-IX, as shown inFIGURE 9. This means that there will be three (3) Wire bushings 152,three (3) right wire hook fingers 164, three (3) left Wire hook fingers164A, as shown in FIGURE 3, and three (3) sets of pins 412 and 410, asshown in FIGURE 9, to elfect the machine operation.

At the crossover points between slots III and IV, VI and VII and I andIX, each turn of one coil will lap over each turn of the other coil oneach side of the unit 24 as the stator unit 24 is oscillated from 0degrees to degrees and returned; and in the winding of each turn of thecoil on the unit 24, the unit and the associated machine members aremanipulated from the starting position illustrated diagrammatically byFIGURE 11A through the positions of FIGURES 11B and 11C and by thesuccessive positions of FIGURES 12A, 12B, 12C and 12D to the finishposition of FIGURE 12E, as explained hereinafter. After the necessaryturns have been wound the stator unit and associated machine memberswill be in the position illustrated diagrammatically in FIGURE 12E atthe completion of the operation. The three (3) coils will looksubstantially, as shown by the drawing of FIGURE 9.

Some of the features of the operation of the machine which should bepointed out are as follows:

(1) The wire hook finger assemblies 160 and 160A arranged at oppositesides of the stator unit 24 have three (3) separate motions, mainlyrotation, vertical and lateral motions. The function of theseassemblies, as shown diagrammatically in FIGURES 11A to C and 12A to E,is to pick the wire 425 up after the shuttle 125 has brought the wire425 through the slot of the stator unit 24 which together with theoscillating motion of the statornest assembly 25, serves to lay the wire425 in the channels, grooves or innermost wire end turn receiving zones435 and 437 provided on the left and right end caps or end turn formingrings 420 and 422. This operation of the machine causes the coils tocross over each other to be wound as described.

(2) The wires 425 are guided and enter slots of the stator unit 24 bythe movement of the shuttle cap bushing 152 from position 1-A toposition 1-B of FIGURE 11B and the return movement of the bushing 152from position 1E to position 1-S of FIGURE 128 before the fingers 164and 164A are rotated away from alignment with the respective slots IIIand VII, as shown from positions 1-A to 1-C and 1-S to 1-T, of therespective drawings of FIGURES 11A and 12A.

In the winding operation, the machine stops at the finish position shownin the drawing of FIGURE 12E after winding the three (3) coils aspreviously described and shown in the drawing of FIGURE 9.

' It will be noted that in FIGURE 11A the right hook finger 164 is shownin its outer radial position l-A in line with the stator slot III andangularly positioned with reference to the end turn forming ring 420 tothe position 1-C to release the wire held thereby, as indicated bydotted lines in FIGURE 11A, after movement of the wire bushing 152 fromthe position l-A to the position 1-B, as indicated in FIGURE 11B. Thewinding of three (3) additional coils at the 120 degree pitch iscompleted in the same manner as the three (3) coils at the 160 degreepitch except that there are no crossover turns and instead of beingwound in the inner grooves or the innermost wire end turn receivingzones 435 and 437 of the forming rings 420 and 422, (3) additional coilsare wound in outer grooves or the outermost wire end turn receivingzones 439 and 441 of the forming rings 420 and 422, as shown in thedrawings of FIGURES 8 and 10, and hereinafter described.

In order to simplify the description of the operation of the machine,the winding of one turn only will be described with reference toschematic drawings FIGURES 11A to C and 12A to E and the machineassembly drawings FIGURES 1 through 8. The numbers on the severaldrawings refer to positions of the various functional elements withreference to each other. The wire indicated in FIGURES 11A, 11B and 123by the numeral 425 and which is to be wound on the unit 24 is fed from asuitable shuttle tension device (not shown) through a longitudinal borein the shuttle 125 and out wire bushing 152 located in the shuttle cap150.

As shown in FIGURE 11A, the wire 425 is wound over pin 412 located inline with the stator slot number III as well as slots VI and IX, asshown in FIGURE 9, of the stator unit 24 in the stator nest 26 and anend of wire 425 in each case is fastened to pin 410. The stator nest 26which is comprised namely of the stator unit 24, right end turn formingring 420 and left end turn forming ring 422 is oscillated back andforth, as previously described in a predetermined timed relation withthe shuttle cap and wire hook fingers 164 and 164A.

The relative positions of the functional elements at the start of theoperation is shown in FIGURES 11A and 118 in which the wire bushing152of shuttle 125 has started its stroke toward the left end and is atposition 1A (FIGURE 11B) and the wire 425 rests in the right wire hookfinger 164 at position 1-A (FIGURES 11A and B), while the left wire hookfinger 164A is rotated away from slot III of the processed stator unit24 and is held in its outer diameter position 1A (FIG- URE 11C) by leftvertical motion cam 220 (FIGURE 3) and laterally in position 1-A by leftlateral motion cam 250 (FIGURE 3).

Further, at the start of the winding operation, the right wire hookfinger 164 in position l-A, as shown in FIGURE 11A, is in line withstator slot III, pin 412 and wire bushing 152 in position l-A (FIGURE11B), and the finger 164 is held in its outer diameter position 1-A(FIGURE 11A) by right vertical and lateral motion cam (FIGURE 3) andlaterally in position 1-A (FIG- URE 11B) by right lateral motion cam(FIGURE 3).

As the machine starts to operate (FIGURE 11B) the wire bushing 152slides to the left through the bore of the stator unit 24 and atposition 1B of the bushing 152 (FIGURE 11B) the wire 425 has definitelyentered slot III of the stator unit 24 at which time right wire hookfinger 164 through the action of cam 310 (FIG- URE 5) starts to rotateaway from position 1-A toward position 1-C (FIGURE 11A). This operationwhen complete will allow wire 425 which was over wire hook finger pinelement 165 to be free thereof. Shortly after as wire bushing 152continues through the bore of the stator unit 24 toward the position 1E(FIGURE 118) the left wire hook finger 164A starts to drop from position1-A (FIGURE 11C) to position 1-D. The left wire hook finger 164A reachesits lower position 1-D of FIGURE 11C and starts to rotate 5 degreesthrough the action of cam 350 (FIGURE 6) before the shuttle cap 150 withwire bushing 152 reaches its extreme left position 1-E (FIGURE 11B).Timing is close, but due to the lateral position of the wire bushing 152in reference to wire hook finger 164a there is no interference. Theright wire hook finger 164 starts to move laterally away from the statorunit 24 due to action "of the right lateral motion cam 190 (FIGURE 3).At position l-C the right hook finger 164 (FIGURE 11A) has rotatedcompletely away from wire 425 and thereafter proceeds to the extremeright position 1G (FIGURE 11B) in the course of the operation of themachine.

The wire 425 has now been guided into slot III of stator unit 24 and 5degrees before the wire bushing 152 reaches its extreme left position1-E (FIGURE 11C) the left wire hook finger 164A at position 1-D (FIG-URE 11C) through the action of cam 350 starts to rotate in a clockwisedirection to a position 1-F (FIGURE 11C) under wire 425 and in line withslot III of the stator unit 24. At the same time at position 1-D (FIG-URE 11C) the left hook finger 164A has reached its lower position. Atposition 1-E (FIGURE 11B) the wire bushing 152 has reached its extremeleft position while at such time the right wire hook finger 164 hasmoved to the extreme right position 1-G (FIGURE 11B).

At position 1-F (FIGURE 11C) the left wire hook finger 164A hascompleted its rotation under wire 425 and left vertical and lateralmotion cam 220 (FIGURE 3) starts to raise the finger 164A towardposition 1-H (FIG- URE 11C) and it in turn raises the wire 425. Afterthe left hook finger 164A has reached its highest position 1-H (FIGURES11B and C) it starts to move laterally from 13 position 1-H (FIGURE 11B)to the right or toward stator unit 24 to position 1] (FIGURE 11B) andthe oscillation of the stator unit 24 starts.

The lateral motion of left wire finger 164A continues toward the rightfrom position 1-H (FIGURE 11B) to position 1] (FIGURE 11B) at which timethe stator nest assembly 25 has been oscillated by the action of the cam75 (FIGURE 4) in a counterclockwise direction, as viewed from the leftside of FIGURE 11C, so that slot IV in stator unit 24 lines upapproximately with left hook finger 164A. At this time the wire 425 hasbeen wound from pin 410 to which it is fastened (FIGURE 11A) over guidepin 412 through slot III over projection K of the plastic ring 422(FIGURE 11C) and over the left hook finger 164A. The projection K, asshown in FIGURE 110, has no vertical member as have projections L and Mand is thus arranged so as to compensate for the crossover of coilswound in slot III-VII and IV-IX of the unit 24. Crossover occurs betweenslots III and IV.

With the left hook finger 164A in the position 1] as viewed in FIGURESllB and 12B, the oscillation of the stator nest assembly 25 continues ina counterclockwise direction with the finger 164A (FIGURE 12A) layingthe wire 425 in the inner channel 437, shown in FIGURE 8, and providedin the projections L and M of the left end turn forming ring 422, asshown in FIGURE 10, until the slot VII approaches the left hook finger164A (FIGURE 12A).

The left hook finger 164A is thereupon moved to the left from position1-I (FIGURE 12B) to position 1-R, as shown in FIGURE 12B, by operationof the left lateral motion cam 250 (FIGURE 3) at which time rotation bythe action of the cam 75 (FIGURE 4) of the stator ne-st assembly 25stops with slot VII of the stator unit 24 lined up with the left hookfinger 164A (FIGURE 12A) in position 1-S (FIGURE 12A). At this time thewire bushing 152 has moved from position 1-E (FIGURE 1213) toapproximately position 1-R, as shown in FIG- URE 12B.

The wire bushing 152 continues to move toward the right and at position1-S of the wire bushing 152 (FIG- URE 12B) the left hook finger 164A bythe action of cam 350 (FIGURE 6) starts to rotate away from the wire 425which at this point 1-S (FIGURE 12A) is over it to a position 1-T(FIGURE 12A) thereby dropping the wire 425. The right hook finger 164 inturn starts to drop from position 1-G (FIGURES 11B and 12D) towardposition 1X (FIGURES 12C and 12D) as the wire bushing 152 continues tomove toward the right from the position l-S (FIGURE 12B) to position 1T,(FIGURE 12C) and left wire hook finger 164A has rotated from position1-S (FIGURE 12A) to approximately position 1.T away from wire 425, asshown in FIGURE 12A.

The wire 425 now has been wound through slot III (FIGURE 11A) of thestator unit 24 and over projections K, L, M and N (FIGURE 12A) andthrough slot VII of the stator unit 24 (FIGURE 12C). Thereafter, theleft lateral motion cam 250 (FIGURE 3) moves the left hook finger 164Afurther to the left from position 1-R (FIG- URE 12B) to position 1-A andcounterclockwise rotation of the finger 164A by the action of cam 350from position 1-T (FIGURE 12A) is completed at position 1-A (FIG- URE12A). On the other hand, the right wire hook finger 164 is dropped fromthe position 1G (FIGURE 12D) to the position 1-X (FIGURE 12D) degreesbefore the shuttle 125 or wire bushing 152 has reached its extreme rightposition 1-T, as shown in FIGURE 120. There is no interference due tothe lateral positions of each element (FIGURES 12C and D). Also, at thistime right hook finger 164 by the action of cam 310 (FIGURE 5) starts torotate from position 1-X (FIG- URE 12D) to a position 1-Z (FIGURE 12D)under the wire 425 and in line with slot VII of the stator unit 24.

Thereafter, the right vertical and lateral motion cam 180 starts toraise finger 164 from position 1-Z (FIG- URE 12D to position 2B (FIGURES12C and D). At position 2-B (FIGURE 12D) the right vertical and lateralmotion cam 180 (FIGURE 3) has raised the right hook finger 164 to itshighest position and the oscillating cam starts to rotate the statornest assembly 25 in a counterclockwise direction as viewed in FIGURE 12Dback to the original position of FIGURE 12E.

Upon the raising of the finger 164 from the position l-Z (FIGURE 12D) tothe position 2B (FIGURES 12C and 12D) the wire 425 is lifted with thefinger 164. Thereafter, the motion of right wire hook finger 164 due tothe motion of the right vertical and lateral motion cam 180 (FIGURE 3)continues toward the left from position 2B (FIGURE 12C) to position 2-D(FIGURE 12C) at which time the stator nest assembly 25 has beenoscillated so that slot VI of stator unit 24 lines up approximately withthe right hook finger 164. At this time the wire 425 has been woundthrough stator slot III (FIGURES 11A and 11B) over projections K, L, Mand N (FIGURE 12A) on left ring 422 back through slot VII (FIGURES 12Aand B) over projection N of the right ring 420 (FIGURE 12E) and overright hook finger 164. The projection N has no vertical member as haveprojections L and M and is so arranged as to permit crossover of coilswound in slots at III-VII and VII. Crossover occurs between slots VI andVII of the stator unit 24.

The lateral movement of the right wire finger 164 continues fromposition 2D (FIGURE 12C) toward the left to position 2E (FIGURE 12C) andwith the right finger 164 in the position 2-E, as viewed in FIGURE 12C,the oscillation of the stator nest assembly 25 as viewed in FIGURE 12Dcontinues in a counterclockwise direction with the finger 164 laying thewire in the inner channel 435, shown in FIGURE 8, and provided in theprojections L and M of the right end turn forming ring 420, as shown inFIGURE 9, until the slot III approaches the right hook finger 164 asviewed in FIG- URE 12E.

The right hook finger 164 is now moved from position 2E of FIGURE 12Ctowards the right away from unit 24 to a position 1A (FIGURE 11B) byright lateral motion cam 190 (FIGURE 3), at which time rotation of thestator nest assembly 25 stops and slot III again lines up with the righthook finger 164 and at this time the wire bushing 152 has also moved tothe left approximately to the position 1-A, as shown in FIGURE 11B.

The wire 425 has now been wound through slot III over projections on theleft ring 422 back through slot VII over projections on the right ring420 and the winding machine is ready for re-entrance of the wire 425into slot III again. The balance of turns specified for this coil arewound in stator slotsIII and VII in exactly the same manner as the firstturn previously described.

In order to wind the three (3) additional coils in the stator unit 24 atthe specified 120 degree pitch the following manual adjustment of thewinding machine must be made:

(1) Change the stator oscillating mechanism from degrees to 120 degreesoscillation by removing the thumb nut 110 (FIGURE 1) and sliding thebracket 112 so that cam 76 is brought into operation in place of the cam75, as heretofore described.

(2) Change both left and right vertical and lateral motion cams 220 and250 (FIGURE 6), and and (FIGURE 5) by releasing latches 280 and 285 andpushing rods 291 and 293 connected. to brackets 295 and 297 so that cams270, 272, 274 and 276 are brought into operation as previouslydescribed.

(3) Disengage oscillating drive gear 31 by pushing or sliding the plate115, as shown in FIGURE 3, toward the right and rotating the stator nestassembly 25 in a counterclockwise direction so that the .slot VIII linesup with the wire hook finger 164 instead of slot III. Re-engage theoscillating drive gear 31 by releasing plate 115 and the machine isthereupon ready to wind the three (3) 120 degree pitch coils. It will benoted that as the stator nest assembly and end turn forming ring arerotated, the wire will wind (FIGURE 8) in the outer groove 439 offorming ring 420 and in the outer groove 441 of forming ring 422.

The winding of the three (3) 120 degree pitch coils is completed in thesame manner as the three (3) 160 degree pitch coils, except that thereare no crossover windings and the 120 degree pitch coils are wound inthe outer groove of the forming rings 420 and 422, as shown on thedrawing of FIGURE 10.

The stator unit 24 has now been completely wound and the ends of thecoils are fastened by pins similar to 410 on the stator nest 26. Thestator nest assembly 25 with wound stator unit 24 is now removed fromthe machine. A wedge plug is then inserted in the stator unit 24.

While the coil winding method of the present invention is illustrated asapplied in a mechanism applicable for the winding of a straight slotstator or rotor unit, it will be readily apparent that by changing therelative motion of the shuttle 125 and stator nest assembly 25 to arotative and lateral motion by appropriate modification of the controlcam mechanisms the mechanism and method may be applied to the winding ofsuch a unit having skew slots.

Although the invention has been illustrated and described as applied toa single form of mechanism, various changes in the form and relativearrangements of the parts of the mechanism, which will now appear tothose skilled in the art may be made without departing from the scope ofthe invention. Reference is, therefore, to be had to the appended claimsfor a definition of the limits of the invention.

What is claimed is:

1. A method of winding coils of wire in a device having a central boreand a plurality of slots opening at opposite ends of the device and intothe bore of the device, said device having end turn forming ring membersat opposite ends of the device with a central bore coaxial to thecentral bore of the device and each of said ring members having portionsextending endwise in planes parallel and adjacent to each of the slotsof said device, said portions having innermost, intermediate, andoutermost flanges, an inner groove formed by the innermost and theintermediate flanges and an outer groove formed by the intermediate andoutermost flanges; said method comprising the steps of passing a loop ofwire through the bore of the device from one end of the device to theopposite end thereof and in alignment with the opening of a firstselected slot in the device, lifting the wire at the opposite end of thedevice so that a portion of the wire is deposited along the firstselected slot in the device and relative to the ring member at saidopposite end and to such an extent that another portion of the wire maybe deposited in the inner groove of the ring member at said opposite endupon rotation of said device relative thereto, rotating the devicerelative to the last-mentioned lifted wire so that said other portion ofthe wire is deposited in the inner groove of the ring member at saidopposite end, stopping the rotation of the device upon the lifted wirebeing at a position adjacent the open end of a second selected slot inthe device, passing a portion of the wire back through the bore in thedevice in alignment with the opening of the second slot into the bore ofthe device and releasing the lifted wire at said opposite end of thedevice so that the wire is deposited in the second slot, lifting thewire at the one end of the device and relative to the ring member atsaid one end and to such an extent that another portion of the wire maybe deposited in the inner groove of the ring member at said one end uponrotation of said device relative thereto, rotating the device relativeto the last-mentioned lifted wire so that the wire is deposited in theinner groove of the ring member at said one end until the lifted portionof the wire is adjacent the open end of the first selected slot andrepeating the aforementioned steps for a predetermined number ofwindings of a first coil; thereafter passing a loop of Wire through thebore of the device from one end of the device to the opposite endthereof and in alignment with the opening of a third selected slot inthe device, lifting the wire at said opposite end of the device so thata portion of the wire is deposited along the third selected slot of thedevice and relative to the ring member at said opposite end and to suchan extent that another portion of the wire may be deposited in the outergroove of the ring member at said opposite end upon rotation of saiddevice relative thereto, rotating the device relative to thelast-mentioned lifted wire so that the wire is deposited in the outergroove of the ring member at said opposite end, stopping the rotation ofthe device upon the lifted wire being at a position adjacent the openend of a fourth selected slot in the device, passing the wire backthrough the bore in the device in alignment with openings of the fourthslot and releasing the lifted wire at said opposite end of the device sothat the wire is deposited in the fourth selected slot, lifting the wireat the one end of the device and relative to the ring member at said oneend and to such an extent that another portion of the wire may bedeposited in the outer groove of the ring member at said one end uponrotation of said device relative thereto, rotating the device relativeto the last-mentioned lifted wire so that the wire is deposited in theouter groove of the ring member at said one end until the lifted portionof the wire is adjacent the open end of the third selected slot,releasing the lifted wire and repeating the aforementioned steps for apredetermined number of windings of a second coil.

2. A method of winding a plurality of coils of wire in a device having acentral bore and a plurality of slots opening at opposite ends of thedevice and into the bore of the device, and said device having end turnforming ring members with a central bore coaxial to the central bore ofthe device, and each of said ring members having portions extendingendwise in planes parallel and adjacent to each of the slots of saiddevice, said portions having flanges forming a groove therein; saidmethod comprising the steps of passing wires through the bore of thedevice from one end of the device to the opposite end thereof and inalignment with openings of selected slots in the device, lifting thewires at the opposite end of the device so that portions of the wiresare deposited in the selected slots in the device and relative to thering member at said opposite end and to such an extent that otherportions of said wires may be deposited in the groove of the ring memberat said opposite end upon rotation of said device relative thereto,rotating the device relative to the last-mentioned lifted wires so thatthe other portions of the wires are deposited in the groove of the ringmember at said opposite end, stopping the rotation of the device uponthe lifted wires being at a. position adjacent open ends of otherselected slots in the device, passing portions of each of the wires overone of the previously deposited wires and then back through the bore inthe device in alignment with openings of the other slots, releasing thelifted wires at said opposite end of the device so that the wires aredeposited in the respective other selected slots, lifting the wires atsaid one end of the device and relative to the ring member at said oneend and to such an extent that other portions of said wires may bedeposited in the groove of the ring member at said one end upon rotationof said device relative thereto, rotating the device relative to thelast-mentioned lifted wires so that each of the wires pass over one ofthe previously deposited wires and then are deposited in the groove ofthe ring member at said one end until lifted portions of said wires areadjacent open ends of the first mentioned selected slots, releasing thelifted wires and thereafter repeating the aforementioned steps for apredetermined number of windings of said coils.

3. A method of winding a plurality of coils of wire in a device having acentral bore and a plurality of slots opening at opposite ends of thedevice and into the bore of the device, said device having end turnforming ring members at opposite ends thereof with a central borecoaxial to the central bore of the device, and each of said ring membershaving portions extending endwise in planes parallel and adjacent toeach of the slots of said device, said portions having innermost,intermediate, and outermost flanges, an inner groove formed by theinnermost and the intermediate flanges and an outer groove formed by theintermediate and the outermost flanges; said method comprising the stepsof passing wires through the bore of the device from one end of thedevice to the opposite end thereof and in alignment with openings of afirst set of selected slots in the device, lifting the wires at theopposite end of the device so that portions of the wires are depositedin the first set of selected slots in the device and relative to thering member at said opposite end and to such an extent that otherportions of said wires may be deposited in the inner groove of the ringmember at said opposite end upon rotation of said device relativethereto, rotating the device relative to the last-mentioned lifted wiresso that the wires may be deposited in the inner groove of the ringmember at said opposite end, stopping the rotation of the device uponthe lifted wires being at a position adjacent open ends of a second setof selected slots in the device, passing portions of each of the wiresover one of the previously deposited wires and then back through thebore in the device in alignment with openings of the second set of slotsand releasing the lifted wires at said opposite end of the device sothat the wires are deposited in the respective second set of selectedslots, lifting the wires at said one end of the device and relative tothe ring member at said one end to such an extent that other portions ofsaid wires may be deposited in the inner groove of the ring member atsaid one end upon rotation of said device relative thereto, rotating thedevice relative to the lastmentioned lifted wires so that each of thewires pass over one of the previously deposited wires and then may bedeposited in the inner groove of the ring member at said one end untillifted portions of said wires are adjacent open ends of the first set ofselected slots, releasing the lifted wires and thereafter repeating theaforementioned steps for a predetermined number of windings of a firstgroup of coils; thereafter passing wires through the bore of the devicefrom one end of the device to an opposite end thereof and in alignmentwith openings of a third set of selected slots in the device, liftingthe wires at said opposite end of the device so that portions of thewires are deposited in the third set of selected slots in the device andrelative to the ring member at said opposite end and to such an extentthat other portions of said wires may be deposited in the outer grooveof the ring member at said opposite end upon rotation of said devicerelative thereto, rotating the device relative to the last-mentionedlifted wires so that the wires may be deposited in the outer groove ofthe ring member at said opposite end, stopping the rotation of thedevice upon the lifted wires being at a position adjacent open ends of afourth set of selected slots of the device, passing portions of each ofthe wires back through the bore in the device in alignment with openingsof the fourth set of slots and releasing the lifted wires at saidopposite end of the device so that the wires are deposited in therespective fourth set of selected slots, lifting the wires at said oneend of the device and relative to the ring member at said one end and tosuch an extent that other portions of said wires may be deposited in theouter groove of the ring member at said one end upon rotation of saiddevice relative thereto,

rotating the device relative to the last-mentioned lifted wires so thateach of the wires may be deposited in the outer groove of the ringmember at said one end until lifted portions of said wires are adjacentopen ends of the third set of selected slots, releasing the lifted wiresand repeating the aforementioned steps for a predetermined number ofwindings of a second group of coils.

4. A method of winding an electrical apparatus shell having a pluralityof equally spaced radially extending slots therein which comprisesproviding a pair of similar end turn forming end caps with a centralbore coaxial to the central bore of the device having portions extendingendwise in the planes parallel to and intermediate the slots of saiddevice, said portions having outermost, intermediate and innermostflanges which define outermost and innermost wire end turn receivingzones, said caps being provided with radially extending slots which areadapted to register with the slots in a shell to be wound; applying oneof said caps to each end of the shell to be wound with the slots in saidend caps in register with the slots in said shell, moving winding wireback and forth through said shell and said end caps thereon in a fixedpath with a dwell in the movement thereof beyond each of said end caps,inserting the wire in one slot of a selected pair of shell slots duringthe movement of the wire in one direction, inserting the wire in theother slot of said selected pair of shell slots during the movement ofthe wire in the opposite direction, rotating said shell in one directionthrough a predetermined angle during the dwell in the movement'of thewire adjacent one end cap and rotating said shell in an oppositedirection through said angle during the dwell in the movement of thewire adjacent the other end cap, whereby first one and then the otherslot of said selected pair of shell slots are alternately brought intoregister with said fixed path until a predetermined number of loops ofsaid wire have been wound into said selected pair of said shell slots,lifting portions of said winding wire during the dwell in the movementthereof beyond each of said end caps and to such an extent that endsections of said loops are disposed in the innermost zones of said endcaps between the intermediate and innermost flanges thereof during therotating of said shell in said one direction and in said oppositedirection, and thereafter winding loops of winding wire in anotherselected pair of said shell slots in a like manner, and lifting otherportions of the last-mentioned winding wire during the dwell in themovement thereof beyond each of said end caps and to such an extent thatend sections of the last-mentioned loops of wire are disposed in theoutermost zones of said end caps between the outermost and intermediateflanges thereof during the rotation of said shell in said one directionand in said opposite direction.

5. A method of winding an electrical apparatus shell having a pluralityof equally spaced radially extending slots therein which comprisesproviding a pair of similar end turn forming end caps with a centralbore coaxial to the central bore of the device having portions extendingendwise in the planes parallel to and intermediate the slots of saiddevice, said portions having outermost, intermediate and innermostflanges which define outermost and innermost wire end turn receivingzones, said caps being provided with radially extending slots which areadapted to register with the slots in a shell to be wound; applying oneof said caps to each end of the shell with the slots in said end caps inregister with the slots in said shell, moving winding wire back andforth through said shell and said end caps thereon in a plurality ofstraight paths with a dwell in the movement thereof beyond each of saidend caps, alternately rotating said shell in one direction to bring saidpaths and one slot of each of selected pairs of shell slots intoregister with each other and then rotating said shell in an oppositedirection to bring said paths and the other slot of each of saidselected pairs of shell slots into register with each other during thedwells in the movement of said wire, inserting said wire into one slot19 of each of said selected pairs of shell slots during the movement ofsaid wire in one direction and inserting said wire in the other slot ofeach of said selected pairs of shell slots during the movement of saidwire in an opposite direction until a predetermined number of loops ofwire have been wound into said selected pairs of slots, lifting portionsof said winding wire during the dwell in the movement thereof beyondeach of said end caps and to such an extent that end sections of saidloops are disposed in the innermost zones of said end caps between theinnermost and intermediate flanges thereof during the rotating of saidshell in said one direction and in said opposite direction, andthereafter winding loops of winding wire in other selected pairs ofshell slots in a like manner, and lifting other portions of thelast-mentioned winding wire during the dwell in the movement thereofbeyond each of said end caps and to such an extent that end sections ofthe loops of wire are disposed in the outermost zones of said end capsbetween the intermediate and outermost flanges thereof during therotating of said shell in said one direction and in said oppositedirection.

6. A method of winding an electrical apparatus shell having a pluralityof equally spaced radially extending slots therein which comprisesproviding a pair of similar end turn forming end caps with a centralbore coaxial to the central bore of the device having portions extendingendwise in the planes parallel to and intermediate the slots of saiddevice, said portions having outermost, intermediate and innermostflanges which define outermost and innermost wire end turn receivingzones, said caps being provided with radially extended slots which areadapted to register with the slots in a shell to be Wound; applying oneof said caps to each end of the shell to be wound with the slots in saidend caps in register with the slots in said shell, moving winding wireback and forth through said shell and the end caps thereon in aplurality of straight paths with a dwell in the movement thereof beyondeach of said caps, alternately rotating said shell in one direction tobring each of said paths and first one slot of each of a plurality ofselected pairs of slots into register with each other and then rotatingsaid shell in an opposite direction to bring each of said paths and theother slot of each of said plurality of selected pairs of slots intoregister with each other during the dwells in the movement of the wire,simultaneously inserting said wire into said one slot of each of saidplurality of selected pairs of slots during the movement of the wire inone direction, simultaneously inserting said wire into said other slotof each of said plurality of said selected pairs of slots during themovement of the wire in the opposite direction, until a predeterminednumber of loops of wire have been simultaneously wound into each of saidplurality of selected pairs of shell slots, lifting portions of saidwinding wire during the dwell in the movement thereof beyond each ofsaid end caps and to such an extent that end sections of said loops ofwire are disposed in the innermost zones of said end caps between theinnermost and intermediate flanges thereof during the rotating of saidshell in said one direction and in said opposite direction, andthereafter simultaneously winding a plurality of loops of Winding wirein another plurality of selected pairs of shell slots in a like manner,and lifting other portions of the last-mentioned Winding wire during thedwell in the movement thereof beyond each of said end caps and to suchan extent that end sections of the last-mentioned loops are disposed inthe outermost zones of said end caps between the intermediate andoutermost flanges of said end caps during the rotating of 20 said shellin said one direction and in said opposite direction.

7. A method of winding an electrical apparatus stator shell having aplurality of equally spaced radially extending slots therein whichcomprises providing a pair of similar end turn forming end caps with acentral bore coaxial to the central bore of the device having portionsextending endwise in the planes parallel to and intermediate the slotsof said device, said portions having flanges which define outermost andinnermost wire end turn receiving zones, said caps being provided withradially extended slots which are adapted to register with the slots ina shell to be wound; applying one of said caps to each end of the shellto be wound with the slots in said end caps in register with the slotsin said shell, moving winding wire back and forth through said shell andthe end caps thereon in a plurality of straight paths with a dwell inthe movement thereof beyond each of said caps, alternately rotating saidshell in one direction to bring each of said paths and first one slot ofeach of a plurality of selected pairs of slots into register with eachother and then rotating said shell in an opposite direction to bringeach of said paths and the other slot of each of said plurality ofselected pairs of slots into register with each other during the dwellsin the movement of the wire, simultaneously inserting said wire intosaid one slot of each of said plurality of selected pairs of slotsduring the movement of the wire in one direction, simultaneouslyinserting said Wire into said other slot of each of said plurality ofsaid selected pairs of slots during the movement of the wire in theopposite direction, until a predetermined number of loops of wires havebeen simultaneously wound into each of said plurality of selectedpairsof shell slots, lifting portions of said winding wire during the dwellin the'movement thereof beyond each of said end caps and to such anextent that end sections of said loops of wire are disposed in one ofthe zones of said pair of wire end turn receiving zones in each of saidend caps during the rotating of said shell in said one direction and insaid opposite direction, and thereafter simultaneously winding aplurality of loops of winding wire in another plurality of selectedpairs of shell slots in a like manner, and lifting other portions of thelast-mentioned winding wire during the dwell in the movement thereofbeyond each of said end caps and to such an extent that end sections ofthe last-mentioned loops are disposed in the other zone of said pair ofWire end turn receiving zones in each of said end caps during therotating of said shell in said one direction and in said oppositedirection.

References Cited by the Examiner UNITED STATES PATENTS 2,304,520 12/1942Wirtz et al 242-1.1 2,624,518 1/1953 Scofield et al 242-1.1 2,647,6968/1953 Brunand 242-].1 2,723,804 11/1955 Martin L 2421.1 2,810,84810/1957 Roberts 310-260 2,952,069 9/1960 Young 29-155.5

FOREIGN PATENTS 710,366 9/ 1941 Germany.

563,932 9/ 1944 Great Britain. 568,733 4/1945 Great Britain.

WHITMORE A. WILTZ, Primary Examiner.

JOHN F. CAMPBELL, Examiner.

1. A METHOD OF WINDING COILS OF WIRE IN A DEVICE HAVING A CENTRAL BOREAND A PLURALITY OF SLOTS OPENING AT OPPOSITE ENDS OF THE DEVICE AND INTOTHE BORE OF THE DEVICE, SAID DEVICE HAVING END TURN FORMING RING MEMBERSAT OPPOSITE ENDS OF THE DEVICE WITH A CENTRAL BORE COAXIAL TO THECENTRAL BORE OF THE DEVICE AND EACH OF SAID RING MEMBERS HAVING PORTIONSEXTENDING ENDWISE IN PLANES PARALLEL AND ADJACENT TO EACH OF THE SLOTSOF SAID DEVICE, SAID PORTIONS HAVING INNERMOST, INTERMEDIATE, ANDOUTERMOST FLANGES, AN INNER GROOVE FORMED BY THE INNERMOST AND THEINTERMEDIATE FLANGES AND AN OUTER GROOVE FORMED BY THE INTERMEDIATE ANDOUTERMOST FLANGES; SAID METHOD COMPRISING THE STEPS OF PASSING A LOOP OFWIRE THROUGH THE BORE OF THE DEVICE FROM ONE END OF THE DEVICE TO THEOPPOSITE END THEREOF AND IN ALIGNMENT WITH THE OPENING OF A FIRSTSELECTED SLOT IN THE DEVICE, LIFTING THE WIRE AT THE OPPOSITE END OF THEDEVICE SO THAT A PORTION OF THE WIRE IS DEPOSITED ALONG THE FIRSTSELECTED SLOT IN THE DEVICE AND RELATIVE TO THE RING MEMBER AT SAIDOPPOSITE END AND TO SUCH AN EXTENT THAT ANOTHER PORTION OF THE WIRE MAYBE DEPOSITED IN THE INNER GROOVE OF THE RING MEMBER AT SAID OPPOSITE ENDUPON ROTATION OF SAID DEVICE RELATIVE THERETO, ROTATING THE DEVICERELATIVE TO THE LAST-MENTIONED LIFTED WIRE SO THAT SAID OTHER PORTION OFTHE WIRE IS DEPOSITED IN THE INNER GROOVE OF THE RING MEMBER AT SAIDOPPOSITE END, STOPPING THE ROTATION OF THE DEVICE UPON THE LIFTED WIREBEING AT A POSITION ADJACENT THE OPEN END OF A SECOND SELECTED SLOT INTHE DEVICE, PASSING A PORTION OF THE WIRE BACK THROUGH THE BORE IN THEDEVICE IN ALIGNMENT WITH THE OPENING OF THE SECOND SLOT INTO THE BORE OFTHE DEVICE AND RELEASING THE LIFTED WIRE AT SAID OPPOSITE END OF THEDEVICE SO THAT THE WIRE IS DEPOSITED IN THE SECOND SLOT, LIFTING THEWIRE AT THE ONE END OF THE DEVICE AND RELATIVE TO THE RING MEMBER ATSAID ONE END OF THE DEVICE AND RELATIVE TO THE RING PORTION OF THE WIREMAY BE DEPOSITED IN THE INNER GROOVE OF THE RING MEMBER AT SAID ONE ENDUPON ROTATION OF SAID DEVICE RELATIVE THERETO, ROTATING THE DEVICERELATIVE TO THE LAST-MENTIONED LIFTED WIRE SO THAT THE WIRE IS DEPOSITEDIN THE INNER GROOVE OF THE RING MEMBER AT SAID ONE END UNTIL THE LIFTEDPORTION OF THE WIRE IS ADJACENT THE OPEN END OF THE FIRST SELECTED SLOTAND REPEATING THE AFOREMENTIONED STEPS FOR A PREDETERMINED NUMBER OFWINDINGS OF A FIRST COIL; THEREAFTER PASSING A LOOP OF WIRE THROUGH THEBORE OF THE DEVICE FROM ONE END OF THE DEVICE TO THE OPPOSITE ENDTHEREOF AND IN ALIGNMENT WITH THE OPENING OF A THIRD SELECTED SLOT INTHE DEVICE, LIFTING THE WIRE AT SAID OPPOSITE END OF THE DEVICE SO THATA PORTION OF THE WIRE IS DEPOSITED ALONG THE THIRD SELECTED SLOT OF THEDEVICE AND RELATIVE TO THE RING MEMBER AT SAID OPPOSITE END AND TO SUCHAN EXTENT THAT ANOTHER PORTION OF THE WIRE MAY BE DEPOSITED IN THE OUTERGROOVE OF THE RING MEMBER AT SAID OPPOSITE END UPON ROTATION OF SAIDDEVICE RELATIVE THERETO, ROTATING THE DEVICE RELATIVE TO THELAST-MENTIONED LIFTED WIRE SO THAT THE WIRE IS DEPOSITED IN THE OUTERGROOVE OF THE RING MEMBER AT SAID OPPOSITE END, STOPPING THE ROTATION OFTHE DEVICE UPON THE LIFTED WIRE BEING AT A POSITION ADJACENT THE OPENEND OF A FOURTH SELECTED SLOT IN THE DEVICE, PASSING THE WIRE BACKTHROUGH THE BORE IN THE DEVICE IN ALIGNMENT WITH OPENINGS OF THE FOURTHSLOT AND RELEASING THE LIFTED WIRE AT SAID OPPOSITE END OF THE DEVICE SOTHAT THE WIRE IS DEPOSITED IN THE FOURTH SELECTED SLOT, LIFTING THE WIREAT THE ONE END OF THE DEVICE AND RELATIVE TO THE RING MEMBER AT SAID ONEEND AND TO SUCH AN EXTENT THAT ANOTHER PORTION OF THE WIRE MAY BEDEPOSITED IN THE OUTER GROOVE OF THE RING MEMBER AT SAID ONE END UPONROTATION OF SAID DEVICE RELATIVE THERETO, ROTATING THE DEVICE RELATIVETO THE LAST-MENTIONED LIFTED WIRE SO THAT THE WIRE IS DEPOSITED IN THEOUTER GROOVE OF THE RING MEMBER AST SAID ONE END UNTIL THE LIFTEDPORTION OF THE WIRE IS ADJACENT THE OPEN END OF THE THIRD SELECTED SLOT,RELEASING THE LIFTED WIRE AND REPEATING THE AFOREMENTIONED STEPS FOR APREDETERMINED NUMBER OF WINDINGS OF A SECOND COIL.